Section 4 -...

“5492RT” Service and Parts Manual October 2010Page 4-1

Section 4

TROUBLESHOOTINGCONTENTS PAGE

General Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4GP400 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Matrix Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Terminal Block Module (TBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6EZ-Cal Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7EZ-Cal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13EZ-Cal Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15EZ-Cal Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Ez-Cal Retrieve Mode And Help Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19MODE Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29Hydraulic Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34Adjusting Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35Drive Pump Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

“5492RT” Service and Parts ManualOctober 2010Page 4--2

FIGURES PAGE

GP400 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Matrix Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Terminal Block Module (TBM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6EZ-Cal Scan Tool Connections - GP400 Module . . . . . . . . . . . . . . . . . . . . . . . 4-7EZ-Cal Display Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8EZ-Cal Flow Chart: Adjustments and Setup, ANSI Models . . . . . . . . . . . . . . . 4-9EZ-Cal Flow Chart: Diagnostic, ANSI Models . . . . . . . . . . . . . . . . . . . . . . . . . 4-10EZ-Cal Flow Chart: Adjustments and Setup, Optional Load Sensing System 4-11EZ-Cal Flow Chart: Diagnostic, Optional Load Sensing System . . . . . . . . . . 4-12Adjustable Valves Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34Charge Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37Brake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38Control Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39Servo Adjustment, Port M5 Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

TABLES PAGE

EZ-Cal Adjustment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13EZ-Cal Setup Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15EZ-Cal Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29Hydraulic Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34


TROUBLESHOOTING - - GENERAL TROUBLESHOOTING TIPS

GENERAL TROUBLESHOOTING TIPS

HYDRAULIC FLUID PUMP

The Hydraulic Drive Pump used in this model is a Variable Displacement, Axial Piston type pump. Proper adjustment is critical for normal operation of the machine. Refer to "Hydraulic Pressure Adjustment" on page 4-34.The Functions/Lift pump is a fixed-displacement gear-type pump attached to the rear of the Drive Pump.

Common Causes of Electrical System Malfunctions:

• Battery switch is turned OFF (located to the left of lower controls).• Battery connections are loose or corroded• Battery is not fully charged.• Emergency Stop buttons are pushed (OFF position).• Circuit breaker is tripped (OFF position).

Common Causes of Hydraulic System Malfunctions:

• Hydraulic fluid level is too low.• Incompatible hydraulic fluids mixed, destroying the additives and causing varnish build up,

resulting in the valves sticking.• Water in the hydraulic fluid due to a damp climate.• Improper hydraulic fluid used. Viscosity too high in cold climates. Viscosity too low in warm

climates.• Hydraulic fluid contaminated with debris - filter change interval neglected.

NOTE: MEC uses a multiple viscosity fluid that is light enough for cold climates and resists thinning in warm climates. Use only the recommended hydraulic fluid. Substituting with a lower grade fluid will result in pump and drive motor failure. Refer to “Lubrication” in the INTRODUCTION Section

NOTE: Contamination always causes failure in any hydraulic system. It is very important to be careful not to introduce any contamination into hydraulic system during the assembly procedures. Please make sure all ports and cavities of the manifold and cylinders are properly covered/plugged during maintenance activities.

“5492RT” Service and Parts ManualOctober 2010-4

TROUBLESHOOTING - - ELECTRICAL SYSTEM TROUBLESHOOTING

ELECTRICAL SYSTEM TROUBLESHOOTING

The electronic control system used on this machine was designed for low maintenance and long, trouble-free operation. The system consists of two microprocessor based modules: the Matrix Module and the GP400 Processor. They communicate through a low voltage digital signal called CAN-Bus communication. To protect against part failure or incorrect plug connections, the modules are fully short circuit and reverse polarity protected. All electrical plug connections are waterproof to promote longer trouble free operation and to increase terminal life.

NEVER ATTEMPT TO SUPPLY BATTERY POWER, OR VOLTAGE HIGHER THAN 12 VOLTS TO ANY PART OR MODULE IN THIS SYSTEM, AS CATASTROPHIC FAILURE OF THE MODULES MAY RESULT.USE OF HIGH PRESSURE WASHING EQUIPMENT DIRECTLY ON THE MODULES CAN FORCE WATER INTO SEALED CONNECTION AND CAN CAUSE A TEMPORARY SYSTEM SHUT-DOWN. HIGH PRESSURE WASHING WITHIN THE VICINITY OF THE MODULES IS HIGHLY DISCOURAGED.



GP400 MODULEThe GP400 module is “the brains” of the system. It receives and processes a variety of inputs both from the machine and the operator, then controls all the operative functions of the machine. It also has a feature that allows the technician to access and monitor all functionality of the system, along with a technician-friendly series of fault messages that can be accessed through the use of the EZ-Cal scan tool. Flash codes are also provided in case an EZ-Cal scan tool is not available. Such information can be used for preventative maintenance and troubleshooting should a problem arise. A comprehensive list of EZ-Cal accessible information can be found later in this section.The GP400 operates on 12 volts DC and should never be probed or operated with voltage higher than 14 volts DC

Figure 4-1: GP400 Module

ART_3532

1 3

13 15

1 3

10 12

1 3

13 15

1 3

13 15

1 3

13 15

1 3

13

13

14

13 15

DiagnosticLED

EZ-CalConnection

P1-1 — CAN BUS HP1-2 — CAN BUS LP1-3 — Ground

P2-1 — not usedP2-2 — not usedP2-3 — not used

P5-1 — Lift ValveP5-2 — Steer RightP5-3 — Steer LeftP5-4 — not usedP5-5 — not usedP5-6 — AlarmP5-7 — not usedP5-8 — High SpeedP5-9 — Hour MeterP5-10 — Outrigger Extend valveP5-11 — Outrigger Retract valveP5-12 — not usedP5-13 — not usedP5-14 — Start Inhibit WarnP5-15 — not used

OUTRIGGER VALVESP6-1 — Right Front Outrigger block valve P6-2 — Left Front Outrigger block valve P6-3 — Right Rear Outrigger block valve P6-4 — Left Rear Outrigger block valve P6-5 — not usedP6-6 — not usedP6-7 — not usedP6-8 — Brake valveP6-9 — not usedP6-10 — not usedP6-11 — not usedP6-12 — not usedP6-13 — Axle LockP6-14 — not usedP6-15 — Generator

BASE & LOWER CONTROLSP7-1 — Valve Supply TBM B+P7-2 — Base SelectedP7-3 — UP - BaseP7-4 — Platform SelectedP7-5 — not usedP7-6 — not usedP7-7 — DOWN - BaseP7-8 — not usedP7-9 — not usedP7-10 — Choke/PreheatP7-11 — not usedP7-12 — StartP7-13 — Oil Pressure SwitchP7-14 — not usedP7-15 — not used

P4-1 — Choke/PreheatP4-2 — StarterP4-3 — not usedP4-4 — ThrottleP4-5 — not usedP4-6 — not usedP4-7 — Alt ExciterP4-8 — IgnitionP4-9 — Drive ForwardP4-10 — Drive ReverseP4-11 — not usedP4-12 — ProportionalP4-13 — not usedP4-14 — Down Valve 1P4-15 — not used

P8-1 — not usedP8-2 — Elevation 1P8-3 — not usedP8-4 — not usedP8-5 — CE Elevation 2P8-6 — Pressure TransducerP8-7 — not usedP8-8 — TBM Analog INP8-9 — TBM Current MeasureP8-10 — not usedP8-11 — not usedP8-12 — not usedP8-13 — Ground B-P8-14 — Ground B-P8-15 — Ground B-

P15-5 — Left Rear Outrigger SwitchP15-6 — Right Rear Outrigger SwitchP15-7 — Right Front Outrigger SwitchP15-8 — Left Front Outrigger SwitchOther terminals not used.

“5492RT” Service and Parts ManualOctober 2010Page 4-6


MATRIX MODULEThe Matrix Module is the remote module located inside the upper control box. It received inputs from the operator and relays them to the GP400.

Figure 4-2: Matrix Module

TERMINAL BLOCK MODULE (TBM)Figure 4-3: Terminal Block Module (TBM)

There is a module inside the lower control box called a TBM (Terminal Block Module) that provides terminal point connections for both positive and ground circuits. A signal from the Emergency Stop circuit activates a load-reduction relay within the TBM that provides ample power to the B+ (positive) terminal strip. This arrangement protects the system against voltage drop conditions that can be detrimental to the electrical system.

ART_3533Matrix Module (inside Upper Control Box)

1

10

31346

12

110

312

17

39

DiagnosticLED

P4-1 — not usedP4-2 — not usedP4-3 — not usedP4-4 — Level Indicator LampP4-5 — Alarm -- CE onlyP4-6 — DriveEnabled Lamp (Outriggers Option)P4-7 — Overload LampP4-8 — not usedP4-9 — not used

P3-1 — Switch SupplyP3-2 — Switch SupplyP3-3 — StartP3-4 — Drive / Left Front UpP3-5 — Lift / Left Front DownP3-6 — Choke/Glow / Right Front UpP3-7 — Generator / Right Front DownP3-8 — Left Rear UpP3-9 — Left Rear DownP3-10 — Right Rear UpP3-11 — Right Rear DownP3-12 — Common

P1-1 — 12 Volts DC INPUT: Power-upP1-2 — not usedP1-3 — CAN BUS HP1-4 — GroundP1-5 — not usedP1-6 — CAN BUS L

P2-1 — FORWARD / DOWNP2-2 — REVERSE / UPP2-3 — STEER LeftP2-4 — STEER RightP2-5 — Enable BarP2-6 — PotentiometerP2-7 — not usedP2-8 — not usedP2-9 — not usedP2-10 — PotentiometerP2-11 — PotentiometerP2-12 — Switch Supply

GROUND(B−) Connection

PLATFORM SelectedBASE SelectedANALOG (AMP)COMMON B+

POSITIVE OUTPUT(B+) SupplyTo various circuits

ART_3186


TROUBLESHOOTING - - EZ-CAL SCAN TOOL

EZ-CAL SCAN TOOL

The EZ-Cal (MEC part # 90888; not part of the machine) is a hand-held scan tool that interfaces with the system to provide various information and adjustments. The EZ-cal receives its power from the GP400 when connected. The system must be powered up by closing the Battery disconnect switch and pulling out both emergency stop switches. You must also select Base or Platform depending on the station you will operate from.

USING THE EZ-CAL SCAN TOOL To operate the EZ-cal, plug the cable into the 4-terminal receptacle P9 on the GP400 and power the system up.

• The EZ-Cal display will illuminate and read “HELP: PRESS ENTER”. From this point, use the right and left arrows to scroll through the base menus.

• Once the desired base menu is obtained (i.e. ADJUSTMENTS) press Enter to access sub menus.

• Use the right and left arrows to scroll through sub menus, press Enter again. • The up/down arrows are used to change settings only. • Press ESC to back up one level.

Figure 4-4: EZ-Cal Scan Tool Connections - GP400 Module

ART_3154

SYMBOL KEY FUNCTIONS

ESC/ENTER BUTTONSTo move back and forth between menu and sub-menu

LEFT/RIGHT BUTTONSSelect menus and setting to be adjusted

UP/DOWN BUTTONSAdjust setting values

GP400 Control ModuleCalibratorMEC P/N 90888

1 3

13 15

1 3

10 12

1 3

13 15

1 3

13 15

1 3

13 15

1 3

13

13

14

13 15

LED

GP400Module

Diagnostic LED

Lower Controls

TerminalBlock

Module


TROUBLESHOOTING - - USING THE EZ-CAL WITH THE FLOW CHARTS

USING THE EZ-CAL WITH THE FLOW CHARTSUse the EZ-cal Flow Charts as a guide to locate diagnostic information and make adjust-ments. Each box in the flow chart will have 3 bits of information.

Figure 4-5: EZ-Cal Display Example

The IDENTIFIER (5c2): – Used to locate this specific personality in the informational charts. Here you can obtain specific information on the individual personalities.

The PERSONALITY (Up Max): – Identifies the individual personalities.

The DEFAULT SETTING: – The factory setting. If adjustments are made, they must be returned to default setting.

ACCESS LEVEL 1 PROVIDES ACCESS TO CHANGE PERSONALITIES NORMALLY PRESET AT THE FACTORY TO PROVIDE PROPER MACHINE MOVEMENT AT SAFE SPEEDS. PERSONALITIES MUST NOT BE CHANGED WITHOUT PRIOR AUTHORIZATION FROM MEC AND MAY ONLY BE RETURNED TO FACTORY SPECIFICATION AS LISTED IN THE FOLLOWING TABLES.

ERROR MESSAGES

To obtain error messages from the EZ-cal Connect the EZ-cal as mentioned above. The display will read, “HELP:PRESS ENTER”. Press Enter to display the current error message. Use the following list of error messages to better understand the fault. Pressing Enter twice will provide a scrolling message of the current error followed by a log of previous errors that may have occurred within recent operation.

FLASH CODES Flash Codes, provided from the GP400 red LED, will also assist in the event an EZ-cal is not available. However, the EZ-cal yields considerably more relevant information. Refer to "EZ-Cal HELP Messages" on page 4-22 for flash coded error messages.

UP MAX75%

5C-2 Identification Number

Personality

Default Setting

to match with information tables, this number will not appear on the EZ-Cal display

ART_3183



Figure 4-6: EZ-Cal Flow Chart: Adjustments and Setup, ANSI Models

ART_3534

Adjustments & Setup Models

TRIP@0%

LAMP@0%

ALARM@0%

@HEIGHT0%

DELAY trip1.5 sec

SAFE DOWN0%

DELAY clear1.5 sec

@HEIGHT46%

SCALE100%

OVERLOAD 2

ELEVATION@3%

MAX DRIVE

MAX LIFT101%

ARMGUARD101%

OVERLOAD0%

SAFE DOWN0.0%

OVERLOAD#20.0%

TILT #2101%

5492RT ANSIGP400MENU

HELP:

HELPSYSTEM

PLATFORM

FWD MIN29%

GROUND

INPUTS

ANALOGS

OUTPUTS

MONITOR

LOG

FWD MAX100%

REV MIN30%

REV MAX100%

ACCEL3.0 sec

DECEL.2 sec

FWD MIN28%

FWD MAX32%

REV MIN27%

REV MAX31%

ACCEL1.5 sec

DECEL5.0 sec

AUTOBELOW

0%

AUTO2.0 sec

TIME0.0 sec

@HEIGHT101%

MAX HEIGHT101%

POSITRAC

UP MIN5%

UP MAX100%

DOWN MIN5%

DOWN MAX47%

SPEED50%

DRIVE COMP60%

DRIVE COMPELEVATED

40%

ACCEL1.2 sec

DECEL0.5 sec

OUT MIN20%

OUT MAX100%

IN MIN20%

IN MAX100%

ACCEL3.0 sec

DECEL3.0 sec

X TRIP2.0º

Y TRIP2.0º

DELAY TRIP2.0 sec

DELAY CLEAR0.5 sec

TILT 20.5 sec

@HEIGHT101%

X TRIP 21.5º

Y TRIP 21.5º

ACCEL0.2 sec

DECEL0.2 sec

MAX HEIGHT101%

CUSTOMER4=5492RT

MODELSELECT

CALIBRATELEVEL

AXLE TILT3.0°

TILTSHUTDOWN

ELEV TILTSHUTDOWN

CALIBRATEHEIGHT

ELEVATION @3%

[email protected] sec

CALIBRATELOAD

FAULTY LOAD-100%

DELAY UP0.0 sec

DELAY DOWN0.0 sec

DYNAMICSCALE95%

TRIGGERONLY

10.0 sec

TRIGGERWAIT

0.0 sec

FUNCTIONHOLD0.2 sec

THROTTLEDELAY0.0 sec

STARTERDELAY

10.0 sec

TILTCORRECTION

2=X-

SLOWDOWN5%

ARMGUARD

LOGGEDHELP

DIAGNOSTICS

DRIVE LIFT STEER DECK(not used) OUTRIGGERS

UP65%

OUTRIGGERS3

EXTEND80%

RETRACT65%

LEVEL60%

DEBOUNCE0.40 sec

INITIAL0.5 sec

TILTFILTER

6

X TILTTARGET

0.2º

Y TILTTARGET

0.2º

TILTSLACK

0.3º

DOWN42%

OUT50%

IN50%

ACCEL1.0 sec

DECEL1.0 sec

GROUNDMODE TILT OVERLOAD

DRIVE

LIFT

TILT1: WHEN

ELEVATED

0: NO

2: DOWN

ALARMS HEIGHTS

CHANGEDEFAULTS

TILTSETUPS

HEIGHTSETUPS

LOADSETUPS INTERLOCKS

DRIVEELEVATED

ACCESS LEVEL RUN SYSTEMTEST

ADJUSTMENTS SETUPS

MIN LIFT1.0 sec

1: LIFT & DRIVE

1: 2: 3:

0: NEVER

4: 5: 6: 7: 5492RT US 8:

SCALE100%

OVERLOAD 2

OVERLOAD#20.0%

TILT #2101%

MAX DRIVE

ARMGUARD101%

101% STD

ENTER ENTER ENTER ENTER

ENTER

1 2 3 4 5 6

6A

5A 5B 5C 5D 5E 5F 5G 5H 5I 5J 5K

6B 6C 6D 6E2A

6A-1

5A-2

5A-3

5A-4

5A-5

5A-6

5A-7

5A-8

5F-1

5F-2

5F-4

5F-3

5F-5

5F-6

5G-1

5G-2

5G-3

5G-4

5H-1

5H-2

5H-3

5H-4

5H-5

5H-5a 5H-5b 5H-5c

5J-1

5J-2

5J-3

5G-5

5G-65F-7

5I-1

5I-2

5I-3

5I-4

5I-8

5I-6

5I-5

5I-7

5K-1

5K-2

5K-3

5K-4

5K-5

5K-6

5K-7

5K-8

5E-1

5E-2

5E-3

5E-4

5E-5

5E-6

5D-1

5D-2

5D-3

5D-4

5D-5

5C-8b5C-8a

5I-8b5I-8a

5F-8

5C-1

5C-2

5C-3

5C-4

5C-5

5C-6

5C-7

5C-8

5B-1

5B-2

5B-3

5B-4

5B-5

5B-6

5A-8b5A-8a

5A-1

5F-9

5F-10

6A-2

6B-1

6B-4

6B-2

6B-3

6C-2

6C-1

6C-3

6C-4

6C-5

6D-1

6D-2

6D-4

6D-5

6D-3

6E-1

6E-2

6E-3

6E-4

6E-5

6C-6

2B

2C

2D

2E

2F

2G

2H

See Chart 2

ENTER


EZ-Cal Flow ChartChart 1 of 2

ESC/ENTER BUTTONSTo move back and forth betweenmenu and sub-menuLEFT/RIGHT BUTTONSSelect menus and setting to be adjusted




Figure 4-7: EZ-Cal Flow Chart: Diagnostic, ANSI Models

ART_3535

DIAGNOSTIC Models5492RT ANSIGP400

MENU

DIAGNOSTICS

2

ENTER

2A-1

2A-2

2A-3

2A-4

2A-5

2A-6

2A-7

2A-8

2A-9

2A-10

2A-11

2A-2a

2A-2b

2A-7a

2A-7b

2A-9a

2A-9b

2A-12

2A-13

2A-14

2A-15

2B-1

2B-2

2B-3

2B-4

2B-5

2C-1

2C-2

2C-3

2C-4

2C-5

2B-6

2B-7

2B-8

2B-9

2A-14a

2A-14b

2A-14c2A-15a

2A-15b

2A-15c

2A-14d

2A-14e

SYSTEM2A

PLATFORM2B

GROUND2C

LOG2G

2G-2

2G-3

2G-1MODE

SUPPLY

VALVESUPPLY

MOTOR VOLTS(ES ONLY)

MOTOR AMPS(ES ONLY)

TEMPERATURE(ES ONLY)

TILT

TILTEDY or N

HEIGHT(CE ONLY)

LOAD(CE ONLY)

OVERLOADEDY or N

(CE ONLY)

CAL DATE(CE ONLY)

SOFTWARE

POWERED

SUPPLY12 V DC

SUPPLYCAP BANK

TILTFILTERED

TILTLOCAL

HEIGHT#1

HEIGHT#2

NOTUSED

ELEVATEDY or N

OUTRIGGERY or N

AXLE

TRIGGERON / OFF

DLD

JOYSTICK

FWD / DWNOFF / ON

REV / UPOFF / ON

UPON / OFF

DOWNON / OFF

NOTUSED

NOTUSED

NOTUSED

LEFTOFF / ON

RIGHTOFF / ON

POSITRACY or N

NOTUSED

RETRACTEDY or N

EXTENDEDY or N

STATUS

LEVEL / OFF LEVEL

LOCKEDY or N

ANGLE

OUTRIGGERTEST

AUTORETRACT

2D-1

2D-2

2D-3

2D-4

2D-5

2D-6

2D-7

2D-8

2D-9

2D-10

2D-11

2F-1

2F-3

2F-5

2F-7

2F-9

2F-10

2F-12

2F-14

2F-16

2F-18

2F-20

2F-22

2F-2

2F-4

2F-6

2F-8

2F-11

2F-13

2F-15

2F-17

2F-19

2F-21

2F-24

2F-25

2F-23

INPUTS2D

ANALOGS2E

OUTPUTS2F

2E-2

2E-3

2E-1P7-1

12 V SUPPLY

LOAD SENSE

P7-2BASE

SELECTED

P7-3UP

SELECTED

P7-4PLATFORMSELECTED

P7-7DOWN

SELECTED

P7-10CHOKE

P7-12THROTTLE

P7-13OIL PRESSURE

SWITCH

P15-5L/R O.R. UP

P15-6R/R O.R. UP

P15-7R/F O.R. UP

2D-12P15-8

L/F O.R. UP

P4-1CHOKE/PREHEAT

P4-4THROTTLE

P4-8IGNITION

P8-2ANGLE

TRANSDUCER

P8-5ANGLE

TRANSDUCER

P8-6PRESSURE

TRANSDUCER

P4-10DRIVE REV

P4-14DOWN

P5-1LIFTS

P5-3STEER LEFT

P5-8HIGH SPEED

P5-10O.R. EXT

P5-12LIMIT

SWITCH,TBM

P6-1RF O.R. VALVE

P6-3RR O.R. VALVE

P4-2START

P4-7ALT EXCITE

P4-9DRIVE FWD

P4-12PROPORTIONALS

P5-2STEER RIGHT

P5-6ALARM

P5-9HOUR METER

P5-11O.R. RETR

P5-14START DELAY

LIGHT

P6-2LF O.R. VALVE

P6-13AXLE LOCK

P6-15GENERATOR

P6-4LR O.R. VALVE

1 3

13 15

1 3

10 12

1 3

13 15

1 3

13 15

1 3

13 15

1 3

13

13

14

13 15

GP400MICROPROCESSOR

ALL CIRCUITS 12 V ONLY

ON = Valve activatedON = Valve activatedON = Valve activatedON = Valve activatedON = Valve poweredON = Generator activated

P6-1P6-2P6-3P6-4P6-13P6-15

RIGHT FRONT OUTRIGGER VALVELEFT FRONT OUTRIGGER VALVERIGHT REAR OUTRIGGER VALVELEFT REAR OUTRIGGER VALVEAXLE LOCK VALVESGENERATOR RELAY SIGNAL

OUTRIGGER MANIFOLDP6

ON = Voltage, OFF = No VoltageON = Base ControlsON = Up activatedON = Platform ControlsON = Down activatedON = activatedON = Start Switch activated

P7-1

P7-2P7-3P7-4P7-7P7-10P7-12P7-13

BATTERY VOLTAGE from TBM

BASE SELECTEDUP SWITCH (BASE CONTROLS)PLATFORM SELECTEDDOWN SWITCH (BASE CONTROLS)CHOKE/PREHEATSTARTOIL PRESSURE SWITCH

BASE & LOWER CONTROLSP7

ON = Leg extended & set ON = Leg extended & set ON = Leg extended & set ON = Leg extended & set

P15-5P15-6P15-7P15-8

L/R OUTRIGGER UP SWITCHR/R OUTRIGGER UP SWITCHR/F OUTRIGGER UP SWITCHL/F OUTRIGGER UP SWITCH

OUTRIGGER CONTROLSP15

P4-1P4-2P4-4P4-7P4-8P4-9P4-10P4-12

P4-14

CHOKE/PREHEATSTART SWITCHTHROTTLE SOLENOIDALTERNATOR EXCITEIGNITION SWITCHDRIVE FORWARDDRIVE REVERSEPROPORTIONAL VALVE

DOWN VALVES

ON = activatedON = Starter activatedON = Solenoid pulled inON = Alternator activatedON = Power to fuel solenoidON = FWD valve activatedON = REV valve activatedON = Proportional valve activatedON = Down Valves activated

P4

ON = Lift Valve activatedON = Valve activatedON = Valve activatedON = Alarm activatedON = Valve activatedON = Meter is poweredON = Valve activatedON = Valve activatedON = When system poweredON = 30-sec. starter cut-out

P5-1P5-2P5-3P5-6P5-8P5-9P5-10P5-11P5-12P5-14

LIFT VALVESTEER RIGHTSTEER LEFTALARMHIGH SPEEDHOUR METEROUTRIGGER EXTEND VALVEOUTRIGGER RETRACT VALVELIMIT SWITCH, TBM POWER SUPPLYSTART DELAY INDICATOR LIGHT

MANIFOLD & MISCP5





Use in conjunction with Diagnostic Tables for

thorough explaination of readout and values.



Figure 4-8: EZ-Cal Flow Chart: Adjustments and Setup, Optional Load Sensing System

ART_3536

Adjustments & Setup

TRIP@110%

LAMP@0%

ALARM@0%

@HEIGHT8%

DELAY TRIP1.5 sec

SAFE DOWN12%

DELAY CLEAR1.5 sec

ELEVATION@3%

MAX LIFT98%

OVERLOAD8%

SAFE DOWN12%

5492RT Optional Load

Sensing System

GP400MENU

HELP:

HELPSYSTEM

PLATFORM

FWD MIN29%

GROUND

INPUTS

ANALOGS

OUTPUTS

MONITOR

LOG

FWD MAX50%

REV MIN30%

REV MAX50%

ACCEL3.0 sec

DECEL.2 sec

FWD MIN29%

FWD MAX32%

REV MIN29%

REV MAX31%

ACCEL1.5 sec

DECEL5.0 sec

AUTOBELOW

0%

AUTO2.0 sec

TIME0.0 sec

@HEIGHT101%

MAX HEIGHT101%

POSITRAC

UP MIN5%

UP MAX100%

DOWN MIN5%

DOWN MAX47%

SPEED50%

DRIVE COMP60%

DRIVE COMPELEVATED

40%

ACCEL1.2 sec

DECEL0.5 sec

OUT MIN20%

OUT MAX100%

IN MIN20%

IN MAX100%

ACCEL3.0 sec

DECEL3.0 sec

X TRIP2.0º

Y TRIP2.0º

DELAY TRIP2.0 sec

DELAY CLEAR0.5 sec

TILT 20.5 sec

@HEIGHT101%

X TRIP 21.5º

Y TRIP 21.5º

ACCEL0.2 sec

DECEL0.2 sec

MAX HEIGHT98%

CALIBRATELEVEL

AXLE TILT3.0°

TILTSHUTDOWN

ELEV TILTSHUTDOWN

CALIBRATEHEIGHT

ELEVATION @3%

[email protected] sec

CALIBRATELOAD

FAULTY LOAD-100%

DELAY UP0.0 sec

DELAY DOWN0.0 sec

DYNAMICSCALE95%

TRIGGERONLY

10.0 sec

TRIGGERWAIT

0.0 sec

FUNCTIONHOLD0.2 sec

THROTTLEDELAY0.0 sec

STARTERDELAY

10.0 sec

TILTCORRECTION

2=X-

SLOWDOWN5%

ARMGUARD

LOGGEDHELP

DIAGNOSTICS

DRIVE LIFT STEER DECK(not used) OUTRIGGERS

UP65%

OUTRIGGERS3

EXTEND80%

RETRACT65%

LEVEL60%

DEBOUNCE0.40 sec

INITIAL0.5 sec

TILTFILTER

6

X TILTTARGET

0.2º

Y TILTTARGET

0.2º

TILTSLACK

0.3º

DOWN47%

OUT50%

IN50%

ACCEL1.0 sec

DECEL1.0 sec

GROUNDMODE TILT OVERLOAD

DRIVE

LIFT

TILT1: WHEN

ELEVATED

0: NO

2: DOWN

ALARMS HEIGHTS

CHANGEDEFAULTS

TILTSETUPS

HEIGHTSETUPS

LOADSETUPS INTERLOCKS

DRIVEELEVATED

ACCESS LEVEL RUN SYSTEMTEST

ADJUSTMENTS SETUPS

MIN LIFT1.0 sec

1: LIFT & DRIVE

0: NEVER

@HEIGHT46%

SCALE100%

OVERLOAD 2

OVERLOAD#20.0%

TILT #2101%

MAX DRIVE

ARMGUARD101%

101% STD

CUSTOMER4=5492RT

MODELSELECT

1: 2: 3: 4: 5: 6:7: 8: 5492RT CE

ENTER ENTER ENTER ENTER

ENTER

1 2 3 4 5 6

6A

5A 5B 5C 5D 5E 5F 5G 5H 5I 5J 5K

6B 6C 6D 6E2A

6A-1

5A-2

5A-3

5A-4

5A-5

5A-6

5A-7

5A-8

5F-1

5F-2

5F-4

5F-3

5F-5

5F-6

5G-1

5G-2

5G-3

5G-4

5H-1

5H-2

5H-3

5H-4

5H-5

5H-5a 5H-5b 5H-5c

5J-1

5J-2

5J-3

5G-5

5G-65F-7

5I-1

5I-2

5I-3

5I-4

5I-8

5I-6

5I-5

5I-7

5K-1

5K-2

5K-3

5K-4

5K-5

5K-6

5K-7

5K-8

5E-1

5E-2

5E-3

5E-4

5E-5

5E-6

5D-1

5D-2

5D-3

5D-4

5D-5

5C-8b5C-8a

5I-8b5I-8a

5F-8

5C-1

5C-2

5C-3

5C-4

5C-5

5C-6

5C-7

5C-8

5B-1

5B-2

5B-3

5B-4

5B-5

5B-6

5A-8b5A-8a

5A-1

5F-9

5F-10

6A-2

6B-1

6B-4

6B-2

6B-3

6C-2

6C-1

6C-3

6C-4

6C-5

6D-1

6D-2

6D-4

6D-5

6D-3

6E-1

6E-2

6E-3

6E-4

6E-5

6C-6

2B

2C

2D

2E

2F

2G

2H

See Chart 2







Figure 4-9: EZ-Cal Flow Chart: Diagnostic, Optional Load Sensing System

ART_3537

DIAGNOSTIC 5492RT GP400MENU

DIAGNOSTICS

2

ENTER

2A-1

2A-2

2A-3

2A-4

2A-5

2A-6

2A-7

2A-8

2A-9

2A-10

2A-11

2D-1

2D-2

2D-3

2D-4

2D-5

2D-6

2D-7

2D-8

2D-9

2D-10

2D-11

2F-1

2F-3

2F-5

2F-7

2F-9

2F-10

2F-12

2F-14

2F-16

2F-18

2F-20

2F-22

2F-2

2F-4

2F-6

2F-8

2F-11

2F-13

2F-15

2F-17

2F-19

2F-21

2A-2a

2A-2b

2A-7a

2A-7b

2A-9a

2A-9b

2F-24

2F-25

2F-23

2A-12

2A-13

2A-14

2A-15

2B-1

2B-2

2B-3

2B-4

2B-5

2C-1

2C-2

2C-3

2C-4

2C-5

2B-6

2B-7

2B-8

2B-9

2A-14a

2A-14b

2A-14c2A-15a

2A-15b

2A-15c

2A-14d

2A-14e

SYSTEM2A

PLATFORM2B

GROUND2C

INPUTS2D

ANALOGS2E

OUTPUTS2F

LOG2G

2E-2

2E-3

2E-1

2G-2

2G-3

2G-1MODE

SUPPLY

VALVESUPPLY

MOTOR VOLTS(ES ONLY)

MOTOR AMPS(ES ONLY)

TEMPERATURE(ES ONLY)

TILT

TILTEDY or N

HEIGHT(CE ONLY)

LOAD(CE ONLY)

OVERLOADEDY or N

(CE ONLY)

P7-112 V SUPPLY

LOAD SENSE

P7-2BASE

SELECTED

P7-3UP

SELECTED

P7-4PLATFORMSELECTED

P7-7DOWN

SELECTED

P7-10CHOKE

P7-12THROTTLE

P7-13OIL PRESSURE

SWITCH

P15-5L/R O.R. UP

P15-6R/R O.R. UP

P15-7R/F O.R. UP

2D-12P15-8

L/F O.R. UP

P4-1CHOKE/PREHEAT

P4-4THROTTLE

P4-8IGNITION

P8-2ANGLE

TRANSDUCER

P8-5ANGLE

TRANSDUCER

P8-6PRESSURE

TRANSDUCER

CAL DATE(CE ONLY)

SOFTWARE

POWERED

P4-10DRIVE REV

P4-14DOWN

P5-1LIFTS

P5-3STEER LEFT

P5-8HIGH SPEED

P5-10O.R. EXT

P5-12LIMIT

SWITCH,TBM

P6-1RF O.R. VALVE

P6-3RR O.R. VALVE

P4-2START

P4-7ALT EXCITE

P4-9DRIVE FWD

P4-12PROPORTIONALS

P5-2STEER RIGHT

P5-6ALARM

P5-9HOUR METER

P5-11O.R. RETR

P5-14START DELAY

LIGHT

P6-2LF O.R. VALVE

SUPPLY12 V DC

SUPPLYCAP BANK

TILTFILTERED

TILTLOCAL

HEIGHT#1

HEIGHT#2

P6-13AXLE LOCK

P6-15GENERATOR

P6-4LR O.R. VALVE

NOTUSED

ELEVATEDY or N

OUTRIGGERY or N

AXLE

TRIGGERON / OFF

DLD

JOYSTICK

FWD / DWNOFF / ON

REV / UPOFF / ON

UPON / OFF

DOWNON / OFF

NOTUSED

NOTUSED

NOTUSED

LEFTOFF / ON

RIGHTOFF / ON

POSITRACY or N

NOTUSED

RETRACTEDY or N

EXTENDEDY or N

STATUS

LEVEL / OFF LEVEL

LOCKEDY or N

ANGLE

OUTRIGGERTEST

AUTORETRACT

1 3

13 15

1 3

10 12

1 3

13 15

1 3

13 15

1 3

13 15

1 3

13

13

14

13 15





GP400MICROPROCESSOR

ALL CIRCUITS 12 V ONLY

Use in conjunction with Diagnostic Tables for

thorough explaination of readout and values.

ON = Valve activatedON = Valve activatedON = Valve activatedON = Valve activatedON = Valve poweredON = Generator activated

P6-1P6-2P6-3P6-4P6-13P6-15

RIGHT FRONT OUTRIGGER VALVELEFT FRONT OUTRIGGER VALVERIGHT REAR OUTRIGGER VALVELEFT REAR OUTRIGGER VALVEAXLE LOCK VALVESGENERATOR RELAY SIGNAL

OUTRIGGER MANIFOLDP6

ON = Voltage, OFF = No VoltageON = Base ControlsON = Up activatedON = Platform ControlsON = Down activatedON = activatedON = Start Switch activated

P7-1

P7-2P7-3P7-4P7-7P7-10P7-12P7-13

BATTERY VOLTAGE from TBM

BASE SELECTEDUP SWITCH (BASE CONTROLS)PLATFORM SELECTEDDOWN SWITCH (BASE CONTROLS)CHOKE/PREHEATSTARTOIL PRESSURE SWITCH

BASE & LOWER CONTROLSP7

ON = Leg extended & set ON = Leg extended & set ON = Leg extended & set ON = Leg extended & set

P15-5P15-6P15-7P15-8

L/R OUTRIGGER UP SWITCHR/R OUTRIGGER UP SWITCHR/F OUTRIGGER UP SWITCHL/F OUTRIGGER UP SWITCH

OUTRIGGER CONTROLSP15

P4-1P4-2P4-4P4-7P4-8P4-9P4-10P4-12

P4-14

CHOKE/PREHEATSTART SWITCHTHROTTLE SOLENOIDALTERNATOR EXCITEIGNITION SWITCHDRIVE FORWARDDRIVE REVERSEPROPORTIONAL VALVE

DOWN VALVES

ON = activatedON = Starter activatedON = Solenoid pulled inON = Alternator activatedON = Power to fuel solenoidON = FWD valve activatedON = REV valve activatedON = Proportional valve activatedON = Down Valves activated

P4

ON = Lift Valve activatedON = Valve activatedON = Valve activatedON = Alarm activatedON = Valve activatedON = Meter is poweredON = Valve activatedON = Valve activatedON = When system poweredON = 30-sec. starter cut-out

P5-1P5-2P5-3P5-6P5-8P5-9P5-10P5-11P5-12P5-14

LIFT VALVESTEER RIGHTSTEER LEFTALARMHIGH SPEEDHOUR METEROUTRIGGER EXTEND VALVEOUTRIGGER RETRACT VALVELIMIT SWITCH, TBM POWER SUPPLYSTART DELAY INDICATOR LIGHT

MANIFOLD & MISCP5

Optional LoadSensing System


TROUBLESHOOTING - - EZ-CAL ADJUSTMENT

EZ-CAL ADJUSTMENT

Refer to "Using the EZ-cal Scan Tool" on page 4-7.Adjustments are possible in Access Level 1 Only.Before changing personalities, ensure that the correct customer and model have been selected in the SETUPS menu. Any changes to settings will be lost when the model or customer is changed. To reach ADJUSTMENTS, first access Level 1, then press --> for ADJUSTMENTS. Press Enter, then press --> to scroll through the sub-menus. Once the desired sub-menu is found, press Enter again, then --> to scroll through the personalities. Press the Up or Down arrows to change the personality. Press ESC to go back one or more levels to reach other sub-menus.

Table 4-1: EZ-Cal Adjustment Table

OPERATION ID PERSONALITY FACTORY SETTING EXPLAINATION

5ADRIVE

(PLATFORM STOWED)

5A-1 FWD Min 29% Slowest speed possible5A-2 FWD Max 50% Maximum speed potential5A-3 REV Min 30% Slowest speed possible5A-4 REV Max 50% Maximum speed potential5A-5 ACCEL 3.0 sec Ramp-up time to maximum5A-6 DECEL .2 sec Ramp-down time to stop5A-7 MAX Height 101% Maximum drivable height

POSITRACK 5A-8 Positrack — Sub category, press ENTER to accessSub Menu 5A-8a AUTO below 0% Not Used

5A-8b AUTO Not Used Not Used5B

DRIVE ELEVATED

5B-1 FWD Min 28% Slowest speed possible5B-2 FWD Max 32% Maximum speed potential5B-3 REV Min 27% Slowest speed possible5B-4 REV Max 31% Maximum speed potential5B-5 ACCEL 1.5 sec Ramp-up time to maximum5B-6 DECEL 5.0 sec Ramp-down time to stop

5CLIFT

5C-1 UP Min 5% Slowest speed possible5C-2 UP Max 100% Maximum speed potential5C-3 DOWN Min 5% Slowest 2peed Possible5C-4 DOWN Max 47% Maximum speed potential5C-5 ACCEL 1.2 sec Ramp-up time to maximum5C-6 DECEL 0.5 sec Ramp-down time to stop5C-7 MAX Height ANSI: 101% || LS*: 98% Maximum height potential

ARMGUARD (LS*) 5C-8 Armguard — Sub category, press ENTER to access

Sub Menu 5C-8a Armguard Time 0.0 sec Not Used5C-8b Armguard @ Height 101% Not Used

5DSTEER

5D-1 Speed 50% Maximum speed potential5D-2 Drive Compensation 60% Adds additional to drive speed5D-3 Drive Comp Elevated 40% Adds additional to drive speed elevated5D-4 ACCEL 0.2 sec Ramp-up time to maximum5D-5 DECEL 0.2 sec Ramp-down time to stop

5E - DECK 5E- Not Used Not Used Power-out deck (not used)*LS: Optional Load Sensing System



5FOUTRIGGERS

5F-1 Outriggers 3=Drive/Retract Determines specific outrigger program5F-2 Extend 80% O/R speed before all legs down5F-3 Level 60% O/R speed after all legs touch down5F-4 Retract 65% Maximum speed potential 5F-5 Debounce .4 sec. Compensates for switch bounce 5F-6 Initial 0.5 Outrigger movement before leveling5F-7 Tilt filter 6 Compensates for tilt sensor free movement5F-8 X Tilt target 0.2 deg Target level stops movement5F-9 Y Tilt target 0.2 deg Target level stops movement

5F-10 Tilt Slack 0.3 deg Additional compensation5F-11 Outrigger Test Yes/No To initiate outrigger test sequence

5GGROUND MODELower Control

Operations

5G-1 UP 65% Maximum speed potential up5G-2 DOWN 42% Maximum speed potential down5G-3 OUT 0% Power deck operation (not used)5G-4 IN 0% Power deck operation (not used)5G-5 ACCEL 1.0 sec Ramp-up time to maximum5G-6 DECEL 1.0 sec Ramp-down time to off

5HTILT

5H-1 X Trip 2.0 degrees Angle when tilt sensor signals Out Of Level5H-2 Y Trip 2.0 degrees Angle when tilt sensor signals Out Of Level5H-3 Delay Trip 2.0 sec Time delay between Tip and Interlock5H-4 Delay Clear 0.5 sec Time delay between Tip and Interlock OFF

TILT 2 5H-4 Tilt 2 — Sub category, press ENTER to accessSub Menu 5H-5A At Height 101% Not Used

5H-5B X Trip 2 1.5 deg Not Used5H-5C Y Trip 2 1.5 deg Not Used

5IOVERLOAD

ANSI: values = 0

LS*: values apply

5I-1 Trip @ ANSI: 0% || LS*: 110% % of weight over maximum to trigger overload5I-2 Lamp @ ANSI: 0% || LS*: 0% % of weight over maximum to trigger lamp5I-3 Alarm @ ANSI: 0% || LS*: 0% % of weight over maximum to trigger alarm5I-4 @ Height ANSI: 0% || LS*: 8% % of elevation load sense starts monitoring weight5I-5 Safe Down ANSI: 0% || LS*: 12% % of elevation lift-down still operates in overload5I-6 Delay Trip 1.5 sec Delay before overload trip5I-7 Delay Clear 1.5 sec Delay before overload clear

OVERLOAD 2 5I-8 Overload # 2 — Sub category, press ENTER to accessSub Menu 5I-8a @ Height 46% % of height for secondary overload valve

5I-8b Scale 100% % of reduced overload valve5J

ALARMS5J-1 Drive: Yes/No No 1 = FWD 2 = REV 3 = Both 4 = All Motion5J-2 Lift 2 = Down 1 = UP 2 = DOWN 3 = Both 4 = All Motion5J-3 Tilt 1 = When Elevated 1 = When Elevated 2 = Always

5KHEIGHTS

5K-1 Elevation 3% Point at which machine enters elevated mode5K-2 Maximum Drive 101% Maximum drivable height5K-3 Maximum Lift ANSI: 101% || LS*: 98% Maximum elevated height potential5K-4 Armguard 101% Stops descent for 5 sec5K-5 Overload ANSI: 0% || LS*: 8% % of elevation load sense starts monitoring weight5K-6 Safe Down ANSI: 0% || LS*: 12% % of elevation lift-down still operates in overload5K-7 Overload # 2 0% Not Used5K-8 Tilt # 2 ANSI: 0% || LS*: 0% Reduced degree of tilt at % elevation

*LS: Optional Load Sensing System

Table 4-1: EZ-Cal Adjustment Table




EZ-CAL SETUPRefer to "Using the EZ-cal Scan Tool" on page 4-7

Table 4-2: EZ-Cal Setup Table


6ACHANGE

DEFAULTS

6A-1 Customer 4: 5492RT Identifies Base ModelMust be set when GP400 is Replaced

6A-2 Model 7 = ANSI8 = Optional Load Sensing

System

Select from these choices only

6DTILT SETUPS

6B-1 Calibrate Level? Y = ENTER N = ESC Pressing ENTER twice will calibrate level sensorWARNING! Refer to Tilt Sensor Calibration instructions before attempting calibration

6B-2 Tilt Shutdown 2 = LIFT Function shutdown tilted when platform stowed6B-3 Elevated Shutdown 1 = Lift & Drive Function shutdown tilted when platform elevated

6B-4 Axle Tilt 3.0 deg Maximum deflection of axle before elevated drive interlock

6CHEIGHT SETUP

(Optional Load Sensing System

ONLY)

6C-1 Elevation @ 3% % of elevation when machine enters elevated mode.

6C-2 Calibrate Height Optional Load Sensing System procedure

ENTER to begin calibration of height sensors

6C-3 Minimum Lift 1.0 sec Do not change6C-4 Samples 0.10 sec Do not change6C-5 Tilt Correction Disabled Do not change6C-6 Slow Down 10% Do not change

6DLOAD SETUPS

(Optional Load Sensing System

ONLY)

6D-1 Calibrate Load Optional Load Sensing System procedure

ENTER to begin calibration of Optional Load Sensing System

6D-2 Faulty Load -100% Optional Load Sensing System Only--DO NOT CHANGE

6D-3 Dynamic Scale 95% Optional Load Sensing System Only--DO NOT CHANGE

6D-4 Delay Up 0.0 sec Not Used6D-5 Delay Down 0.0 sec Not Used

6EINTERLOCKS

6E-1 Trigger Only 10.0 sec Enable bar held without operation before interlock

6E-2 Trigger Wait 0.0 sec Delay after enable bar pulled before function enabled

6E-3 Function hold 0.2 sec Function enabled after operator release Delays 6E-4 Delays — Sub category, press ENTER to access

Sub Menu 6E-4a Throttle Delay 0.0 sec Delay before throttle enabled

6E-4b Start Delay 10.0 sec Interlocks start to protect start system from overheat



EZ-CAL DIAGNOSTICSThe EZ-Cal Diagnostics menu provides the ability to view and test individual circuits for irregularities. Whether diagnosing a failure or testing functions during preventative mainte-nance, the Diagnostics Menu provides a quick view at the inputs and outputs as registered by the GP400 Control Module in real time. Using the EZ-Cal Flow Chart, compare ID number to this menu for circuit identification and result.To reach DIAGNOSTICS menu from HELP;

• Press the right arrow and scroll to DIAGNOSTICS and press ENTER.• Locate the desired sub menu and press ENTER.• Press the right arrow to scroll through the test points.

NOTE: The ID number will not appear on the EZ-Cal display. It is shown in the Diagnostics Menu for reference only.

Using the ID number, match specific personalities from the Diagnostic Flow Charts with this table for additional information.Press ESC to go back one level (necessary to change selection).

Table 4-3: EZ-Cal Diagnostics Menu

SELECTION

IDEZ-cal

READOUTEXPLAINATION

2ASYSTEM 2A-1 MODE Shows current operation - Press ENTER to read interlock when 2-2 flash is

present2A-2 Supply System Voltage - Press ENTER for Supply sub-menus

Sub Menu2A-2a Supply Voltage through EMS circuit to either Base or Platform input. 12 - 13.5 volts2A-2b Cap Bank Voltage Not used on I/C engine models2A-3 Valve Supply on/off Supply all 12 volt circuits through TBM Module2A-4 Motor Volts Not used on I/C engine models2A-5 Motor 1 Not used on I/C engine models2A-6 Temperature Not used on I/C engine models2A-7 Tilt Current state of tilt as measured by GP400

Sub Menu2A-7a Tilt Filtered Slowed tilt value used for O/R or Auto-level 2A-7b Tilt Local Current state of level as measured by level sensor located inside the GP4002A-8 Tilted Y/N Indicates tilted state. Y=All motorized functions stop when in elevated state2A-9 Height Current state of platform elevation in %.

Sub Menu2A-9a Height 1 % Current state of platform elevation in % as read from EZ-fit #1 (see 2A-9)

2A-9b Height 2 % Current state of platform elevation in % as read from EZ-fit #2- Optional Load Sensing System only

2A-10 Load Current load on platform in %. (Optional Load Sensing System only)2A-11 Overloaded Y/N Platform overloaded. (Optional Load Sensing System only)2A-12 Last Moved Not used2A-13 Elevated Y/N Y=platform in elevated state; tilt cut-out and slow drive enabled2A-14 Outriggers Press ENTER for outriggers sub-menu

Sub Menu

2A-14a Retracted Y/N All Retract switches closed 2A-14b Extended Y/N All pressure switches closed, legs down2A-14c Status For outrigger equipped units only2A-14d Outrigger Test Follow instructions on EZ-cal to test O/R circuits2A-14e Auto-retract 15s Retract in drive mode - auto-retract feature used on 5492 models only2A-15 Axle Press ENTER for Oscillating Axle sub menus

Sub Menu 2A-15a Level / Off Level Status of axle position as read by GP400 2A-15b Locked Y/N Status of oscillating axle lock valves, Y = no oscillation2A-15c Angle Position of oscillating Axle relative to the chassis



2BPLATFORM

2B-1 Trigger ON/OFF Current status of enable trigger - upper controls2B-2 DLD Position of Lift/Drive selector switch2B-3 Joystick Indicates % of stroke from center in real time. Direction not indicated here2B-4 FWD/DWN OFF/ON Status of Forward micro-switch Forward stroke of the joystick2B-5 REV/UP OFF/ON Status of Reverse micro-switch Reverse stroke of the joystick2B-6 LEFT OFF/ON Status of Left Steer switch2B-7 RIGHT OFF/ON Status of Right Steer switch2B-8 Positrac Y/N Not used2B-9 EMSG OFF/ON Not used

2CGROUND

2C-1 UP OFF/ON Status of Up switch from lower control station2C-2 DOWN OFF/ON Status of Down switch from lower control station2C-3 OUT OFF/ON Not used2C-4 IN OFF/ON Not used2C-5 EMSg OFF/ON Not used

2DINPUTS

2D-1 P7-1 12 Volt Supply. Battery voltage from TBM Module2D-2 P7-2 Base Selected. ON= Base/Platform select switch in Base position2D-3 P7-3 Up. On= platform UP switch activated to elevate platform2D-4 P7-4 Platform Selected. ON= Base/Platform selector switch in Platform position.2D-5 P7-7 Down. ON= Down switch activated for platform lower operation2D-6 P7-10 Choke (gas engine) or pre-heat (diesel). ON= Choke or Pre-heat switch activated2D-7 P7-12 Start. ON= input from engine-start switch2D-8 P7-13 Oil Pressure Switch2D-9 P15-5 L/R Outrigger UP Switch. ON=leg extended and set

2D-10 P15-6 R/R Outrigger UP Switch. ON=leg extended and set2D-11 P15-7 R/F Outrigger UP Switch. ON=leg extended and set2D-12 P15-8 L/F Outrigger UP Switch. ON=leg extended and set

2EANALOGS 2E-1 P8-2 Elevation transducer 1 - measures state of elevation in %

2E-2 P8-5 Elevation transducer 2 - measures state of elevation in % (redundant; Optional Load Sensing System only)

2E-3 P8-6 Pressure transducer - measures lift system pressure in % (Optional Load Sensing System only)


SELECTION

IDEZ-cal

READOUTEXPLAINATION



2FOUTPUTS

2F-1 P4-1 Diesel pre-heat. ON= Pre-heat activated2F-2 P4-2 Engine Start. ON= Starter activated2F-3 P4-4 Throttle Solenoid. ON= Throttle solenoid pulled in2F-4 P4-7 Alternator Excite. ON= power to activate alternator charge 2F-5 P4-8 Ignition. ON= power to fuel hold solenoid 2F-6 P4-9 Drive Forward. ON=drive forward valve activated.2F-7 P4-10 Drive Reverse. ON=drive reverse valve activated.2F-8 P4-12 Proportional Valve. ON= Proportional valve activated2F-9 P4-14 Down Valves. ON= Down valves activated for platform lower operation

2F-10 P5-1 Lift Valve. ON= Lift valve activated for platform Lift2F-11 P5-2 Steer Right. ON= steer right valve activated2F-12 P5-3 Steer Left. ON= steer left valve activated

2F-13 P5-6 Alarm. ON= alarm activated (default alarm in Down, may be selected for other modes)

2F-14 P5-8 High Speed. ON= high speed valve activated (drive range toggle in up position)2F-15 P5-9 Hour Meter. ON= Meter powered up2F-16 P5-10 Outrigger Extend Valve. ON=valve open to supply pressure to outrigger legs2F-17 P5-11 Outrigger Retract Valve. ON=valve open to supply pressure to outrigger legs

2F-18 P5-12 Power Supply to limit switch and TBM module - should be ON when system powered

2F-19 P5-14 Start delay indicator light. ON=starter delay interlock for 30 seconds for cool down

2F-20 P6-1 Right-Front Outrigger Valve. ON =leg extending or retracting.2F-21 P6-2 Left-Front Outrigger Valve. ON =leg extending or retracting.2F-22 P6-3 Right-Rear Outrigger Valve. ON =leg extending or retracting.2F-23 P6-4 Left-Rear Outrigger Valve. ON =leg extending or retracting.2F-24 P6-13 Axle Lock Valves. ON=Axle valves powered; axle will oscillate2F-25 P6-15 Generator. On=Generator active.

2GLOG

2G-1 Cal Date Date of Load Sense calibration (Optional Load Sensing System only)2G-2 Software MEC specific software version2G-3 Powered Accumulated time GP400 powered up (red LED on)


SELECTION

IDEZ-cal

READOUTEXPLAINATION


TROUBLESHOOTING - - EZ-CAL RETRIEVE MODE AND HELP MESSAGES

EZ-CAL RETRIEVE MODE AND HELP MESSAGESNOTE: It is important to understand that an error message will only be available if the red Diagnostic

LED is flashing. If the machine is not operating properly and the red Diagnostic LED is not flashing, the trouble may lie with something not monitored by the electronic control system, i.e. a switch, hydraulic valve or wiring damage.

There are two different menus that you can access for message retrieval; MODE and HELP.

MODE MENU

Allows the technician to see the current state of the controller with a short description. Go to, DIAGNOSTICS/SYSTEM/MODE (EZ-Cal Flow Chart 2, ID# 2a-1). Pressing ENTER a second time will provide additional information with certain messages.

HELP MENU

Provides various HELP messages to identify failure modes. Some error messages may also be identified by counting the number of times the red LED flashes on the controller so that even without access to an EZ-Cal, some simple diagnostics are possible. However, it is recommended to use an EZ-Cal to diagnose problems, and not rely on the LED! The EZ-Cal provides a much higher detail of information.

HELP MESSAGE

• Connect the EZ-Cal (see illustration). The display will read, “HELP: PRESS ENTER”.

• Press Enter to display the current message. • Refer to the following list of HELP messages to better understand the nature of the message

or fault. • If the GP400 does not register a fault, the display will read EVERYTHING OK.

Pressing ENTER twice will provide a scrolling message of the current message (if one exists). Pressing RT and LT arrows provides access to a log of previous operations and/or errors that occurred immediately prior, starting with most recent. All messages are cleared whenever the system is powered down.Other helpful menus available include DIAGNOSTICS which allows the technician to monitor specific plug input/output information. Refer to EZ-Cal Flow Chart 2 – Diagnostics (ANSI - Page 4-10; Optional Load Sensing System - Page 4-12).

MODE MESSAGES

The purpose of MODE is to indicate, in real time, the current state of the controller with a short description.INITIALIZING

• The system is preparing to operate, immediately after power-on.SHUTDOWN!

• The system cannot operate – for example both the PLATFORM & GROUND inputs are active together.

CHECK CANBUS

• The system cannot operate – CANBUS communications is not successful (for example wire damage to the platform)



PLATFORM, GROUND

• The system is ready to operate, from the upper or lower controls as indicated (selected by the Base/Platform selector switch)

GROUND UP, GROUND DOWN,

• A ground function is operating normallyGROUND UP LOCKED, GROUND DOWN LOCKED,

• A ground function is selected but not allowed (for example, the function switch was closed at power-on)

GROUND FAULTY

• Multiple ground function inputs are active at the same timeWAITING FOR TRIGGER

• A platform function is selected, but the joystick trigger switch is not closed (close the trigger switch to proceed)

TRIGGER CLOSED

• The joystick trigger switch is closed, but no function is selected (select a function to proceed)TRIGGER LOCKED

• The joystick trigger switch was closed at power-on, or closed for too long with no function selected (check trigger switch)

FORWARD, REVERSE

• A platform drive function is operating normallyFORWARD (LEFT), FORWARD (RIGHT), REVERSE (LEFT), REVERSE (RIGHT)

• A platform drive function is operating normally, with steer also activeSTEER LEFT, STEER RIGHT

• A platform steer function is operating normally (without drive)UP, DOWN

• A platform lift/lower function is operating normallyFORWARD LOCKED, REVERSE LOCKED

• A platform drive function is selected but not allowed (for example, the switch was closed at power-on)

LEFT LOCKED, RIGHT LOCKED

• A platform steer function is selected but not allowed (for example, the switch was closed at power-on)

UP LOCKED, DOWN LOCKED

• A platform lift/lower function is selected but not allowed (for example, the switch was closed at power-on)

CHECK DRIVE/LIFT

• Neither platform drive nor platform lift select is active, or both are active at the same timeCHECK JOYSTICK

• Both platform joystick directions are active at the same timeSTEER FAULTY

• Both platform steer directions are active at the same time



EXTENDING LEGS

• Outrigger legs are extending normallyRETRACTING LEGS

• Outrigger legs are extending normallyOUTRIGGERS LOCKED

• An outrigger function is selected but not allowed (for example, the switch was closed at power-ON)

INTERLOCKED**

• An interlock shutdown is active, preventing one or more functions. The interlock can be due to many different causes …

**Press <ENTER> from the MODE display to see the precise cause of the interlock (listed below) – press <ESC> from that display to return to the MODE display:

TEST MODE

• The system test mode is active – switch power off and on again to clearTILTED

• The vehicle is tilted beyond limits, descend, then move vehicle to a more level locationOVERLOADED

• The vehicle platform is overloaded, reduce platform load. (Optional Load Sensing System option only)

TOO HIGH

• The vehicle platform is too high to allow some functions – descend firstARMGUARD

• During descent, the system is configured to stop movement to provide an armguard delay – release and re-select DOWN to continue lowering (Optional Load Sensing System only)

TOO HOT

• The EZLIFT heatsink has reached 75ºc, preventing all functions except lowering. Functions will be allowed again when the heatsink cools to below 70ºc.

• The heatsink temperature can be viewed in the DIAGNOSTICS/SYSTEM/ TEMPERATURE dis-play, ID # 2a5.

• The heatsink must be bolted to a significant metal panel of the vehicle, capable of dissipating heat to the environment.

UNCALIBRATED

• The height and/or pressure sensors have not been calibrated see CALIBRATION OF OVER-LOAD SYSTEM (Optional Load Sensing System only).

• If machine is not equipped with Overload system, refer to SETUPS table and change those personalities that do not match the figure listed in the table.

EXTERNAL ALL, EXTERNAL DRIVE, EXTERNAL LIFT

• An external cutout input is preventing functions – determine the cause of the external cutout (for example, a limit switch)



EZ-CAL HELP MESSAGES

In addition to the MODE messages detailed above, the GP400 provides a HELP message to identify failure modes. Some error messages may also be identified by counting the number of times the red LED flashes on the controller so that even without access to an EZ-Cal, some simple diagnostics are possible. However, it is recommended to use an EZ-Cal to diagnose problems, and not rely on the LED! The EZ-Cal provides a much higher detail of information.

• Connect the EZ-Cal (see illustration). The display will read, “HELP: PRESS ENTER”.

• Press Enter to display the current message. • Refer to the following list of HELP messages to better understand the nature of the message

or fault. • If the GP400 does not register a fault, the display will read EVERYTHING OK.

Pressing ENTER twice will provide a scrolling message of the current message (if one exists). Pressing RT and LT arrows provides access to a log of previous operations and/or errors that occurred immediately prior, starting with most recent. All messages are cleared whenever the system is powered down.

NOTE: When using the LED to attempt diagnosis, please note that a DUAL FLASH code is indicated. The LED will flash on/off a certain number of times, pause off for a short delay, then flash on/off a second certain number of times, followed by a much longer pause off. The sequence will then repeat.

INFORMATION ONLY MESSAGES

The following are “information only” HELP messages which are not indicative of any possible problem – there is no LED flash code (the LED remains on steady):

STARTUP! _____________________________________________ (no flash code)

• The system has just been powered on and is carrying out some initialization steps prior to being ready to operate. If you select a function during this time, it may be locked out until you release then re-select it.

EVERYTHING OK _______________________________________ (no flash code)

• There is no problem with the system – it is ready to operate in platform mode when a function is selected.

NOTE: If this is the HELP message when a function is selected, check for open-circuit switches or wiring.

GROUND MODE ACTIVE! ________________________________ (no flash code)

• There is no problem with the GP400 – it is ready to operate in ground mode when a function is selected.

CLOSE TRIGGER _______________________________________ (no flash code)

• A platform function is selected but the trigger switch is not closed.VEHICLE TILTED _______________________________________ (no flash code)

• The vehicle is tilted beyond the limits, some functions may be prevented.



FUNCTION ACTIVE MESSAGES

The following HELP messages indicate that there is no problem with the GP400 but that a function is active – the vehicle should be moving as requested by the operator.DRIVING! _____________________________________________ (no flash code)

LIFTING! ______________________________________________ (no flash code)

LOWERING! ___________________________________________ (no flash code)

STEERING! ___________________________________________ (no flash code)

EXTENDING OUTRIGGERS! ______________________________ (no flash code)

RETRACTING OUTRIGGERS! ____________________________ (no flash code)

CALIBRATION MESSAGES

The following are “calibration” HELP messages – until the machine is properly calibrated for height and/or pressure (as required), many functions will not be available.NOT CALIBRATED ______________________________________ Flash Code: 1/1

FUNCTIONS LOCKED - NOT CALIBRATED __________________ Flash Code: 1/1

• The height and/or pressure sensors have not been calibrated and are required because of the setup of the GP400.

• Calibration procedures are accessible from the SETUPS/HEIGHT SETUPS and SETUPS/LOAD SETUPS menus.

FAULT: CUSTOMER _____________________________________ Flash Code: 1/1

• The system must be configured to the customer requirements – with the EZ-Cal in SETUPS/CHANGE DEFAULTS menu, scroll to the correct machine from this menu, the press Right Arrow to select the appropriate model.

NOTE: Selecting the incorrect customer or model will cause the machine to operate incorrectly or go into fault mode.



SHUTDOWN HELP MESSAGES

This section lists “shutdown” HELP messages – functions can be shut down to prevent them being used:SHUTDOWN - CHECK EMS SWITCHES! ____________________ Flash Code: 2/1

• The Base/Platform selector switch position indicates the mode in which the system must operate if both are active together; the system does not know how to function

FUNCTIONS LOCKED - TEST MODE SELECTED _____________ Flash Code: 2/2

• Test mode is not accessible with this system. Switch power off/on to reset to normal operationFUNCTIONS LOCKED - ARMGUARD (optional Load Sensing System only)______________________________________________________ Flash Code: 2/2

• During descent, the System can stop movement for a configurable time, to allow a safety check that no-one is close to the machine. The operator must release and re-select DOWN to continue lowering (after the delay time-out).

FUNCTIONS LOCKED – OVERLOADED (optional Load Sensing System only)______________________________________________________ Flash Code: 2/2

• System overload features are active, and the platform is excessively loaded to allow operation – the platform load must be reduced.

FUNCTIONS LOCKED – UNDERLOADED (optional Load Sensing System only)______________________________________________________ Flash Code: 2/2

• System overload features are active, and the platform load is too low to be valid – this could be caused by erroneous calibration, a sensor fault, or a change in the vehicle mechanics/hydraulics.

FUNCTIONS LOCKED - TOO HIGH _________________________ Flash Code: 2/2

• The platform is raised too high to allow some functions. Certain functions may not be allowed above certain elevations.

• Check operator’s manual or ADJUSTMENTS/HEIGHTS/MAX DRIVE and MAX LIFT to see if drive and/or lift is allowed at all heights.

FUNCTIONS LOCKED - TILTED ___________________________ Flash Code: 2/2

• The vehicle is tilted too much to allow some functions.• Check operator’s manual or ADJUSTMENTS/TILT/Xtrip and Ytrip, which determine the maxi-

mum allowed vehicle tilt. • Refer to EZ-Cal Flow Chart 1 – Adjustments and Setup.

FUNCTIONS LOCKED - EXTERNAL SHUTDOWN _____________ Flash Code: 2/2

• An external shutdown is preventing functions – check DIAGNOSTICS/SYSTEM/ MODE/INTER-LOCK to see which external interlock is active.

CHECK GROUND INPUT SWITCHES! ______________________ Flash Code: 2/2

• There is a problem with the ground function select switches – more than one is active at the same time.

SELECT DRIVE/LIFT MODE! ______________________________ Flash Code: 2/2

• There is a problem with the platform drive/lift select switch – neither mode is selected.CHECK DRIVE/LIFT SELECT SWITCH! _____________________ Flash Code: 2/2

• There is a problem with the platform drive/lift select switch – both modes are selected together.



CHECK JOYSTICK SWITCHES! ____________________________ Flash Code: 2/2

• There is a problem with the platform joystick switches – both directions are selected together.RELEASE TRIGGER! ____________________________________ Flash Code: 2/2

• The trigger was closed at power-on, or closed for too long with no function selected.RELEASE GROUND SWITCHES!___________________________ Flash Code: 2/2

• Ground function switches were closed at power-on.RELEASE JOYSTICK SWITCHES!__________________________ Flash Code: 2/2

• Platform joystick switches were closed at power-on, or closed for too long without trigger switch (see SETUPS/INTERLOCKS/TRIGGERwait).

RELEASE OUTRIGGER SWITCHES!________________________ Flash Code: 2/2

• Outrigger switches were closed at power-on.

WIRING MESSAGES

The following are “wiring” HELP messages – problems have been detected which are likely due to vehicle wiring issues:FAULT: ENERGIZED VALVE - CHECK P5 WIRING! ____________ Flash Code: 3/2

FAULT: VALVE FEEDBACK HIGH - CHECK VALVE WIRING!_____ Flash Code: 3/2

• There is a voltage on one or more valve outputs, when all outputs are off.• Check each valve output to trace where the invalid supply is coming from.

FAULT: CAPBANK VOLTAGE TOO HIGH - CHECK LINE CONT! __ Flash Code: 3/3

• The voltage on the B+ stud of the controller (connected to an internal voltage stabilization capacitor bank) is too high when the line contactor is off. B+ stud voltage should be approxi-mately 32 volts at idle.

• Check the line contactor tips are not welded, and check the power wiring for errors.FAULT: ENERGIZED LINE CONTACTOR - CHECK P5 WIRING! __ Flash Code: 3/4

• There is a voltage on the line contactor coil output, when it is off.• Check wiring to the line contactor coil to trace where the invalid supply is coming from.

FAULT: MOTOR OVERLOAD! ______________________________ Flash Code: 3/5

• The power protection circuits in the controller have activated to protect from extreme over-load.

• Check for short-circuit power wiring; check for a seized or shorted motor.



SUPPLY MESSAGES

The following are “supply” HELP messages – problems have been detected which are likely due to supply issues:

FAULT: LOW OIL PRESSURE!_____________________________ Flash Code: 4/1

• Engine oil pressure switch open after start sequence initiated or engine stalled or unable to start.

FAULT: BAD INTERNAL 5V!_______________________________ Flash Code: 4/2

• The internal “5V slave” supply is out of range; if the fault remains, the controller may have to be replaced.

FAULT: BAD INTERNAL SLAVE! ___________________________ Flash Code: 4/2

• The internal “slave” is not operating correctly; if the fault remains, the controller may have to be replaced.

FAULT: BAD INTERNAL 12V!______________________________ Flash Code: 4/3

• The internal “12V” supply is out of range; • 12V Supply is generated by the Motor control module and supplied to the GP400. Check for

wiring errors between the two modules. If the fault remains, the Motor Controller may have to be replaced.

FAULT: BATTERY VOLTAGE TOO LOW! _____________________ Flash Code: 4/4

• The battery supply is too low – the batteries must be re-charged.FAULT: BATTERY VOLTAGE TOO HIGH! ____________________ Flash Code: 4/4

• The battery supply is too high – check that the correct battery and charger are installed.FAULT: BAD 5V SENSOR SUPPLY - CHECK P2-1 WIRING! _____ Flash Code: 4/5

• The “5V sensor” supply is out of range; this supply is available to power external 5V-powered sensors – check that is has not been overloaded or short-circuited to other wiring (Optional Load Sensing System only).



SENSOR MESSAGES - OPTIONAL LOAD SENSING SYSTEM The following are “sensor” HELP messages – problems have been detected which are likely due to sensor issues (optional Load Sensing System).

FAULT: CHECK HEIGHT1 SENSOR _________________________ Flash Code: 6/1

FAULT: CHECK HEIGHT2 SENSOR _________________________ Flash Code: 6/1

• A height sensor is giving an out-of-range voltage (below 0.5V or above 4.5V).FAULT: CHECK HEIGHT SENSORS_________________________ Flash Code: 6/1

• When two height sensors are fitted, both should read the same height at all times; this mes-sage indicates that the sensors are reading different heights. Check for loose sensors and/or re-calibrate.

FAULT: CHECK PRESSURE SENSOR _______________________ Flash Code: 6/2

• A pressure sensor is giving an out-of-range voltage (below 0.5V or above 4.5V).FAULT: CHECK ELEVATION SWITCH _______________________ Flash Code: 6/3

• The elevation switch is in disagreement with the height sensor(s).• During calibration, the height at which the elevation switch opens (while lifting) and closes

(while lowering), is recorded. Subsequently, height and these calibration points are continu-ously checked – any significant difference generates this error.

CANBUS MESSAGES

This section lists “CANBUS” HELP messages – problems have been detected with CANBUS communications between different modules (of course, only applicable if more than one module is connected together via CANBUS):

FAULT: CANBUS! _______________________________________ Flash Code: 6/6

• There are problems with CANBUS communications between the different modules; messages expected from one or more module are not being received, or messages intended to one or more module cannot be transmitted.

• Check for open- and short- circuit problems with CANBUS wiring; ensure that the CANBUS is wired correctly pin-to-pin; ensure that the vehicle chassis is not erroneously shorted to the chassis (for example, due to insulator breakdown in the motor).

POWER WIRING MESSAGES

The following are “power wiring” HELP messages – problems have been detected which are likely due to power wiring errors:

FAULT: CAPBANK VOLTAGE TOO LOW - CHECK STUD WIRING! Flash Code: 7/7

• The voltage on the B+ stud of the controller (connected to an internal voltage stabilization capacitor bank) is too low when the line contactor is off (a pre-charge circuit in the module normally applies approximately 32 volts to the capacitor bank).

• Check the 300 amp fuse, line contactor or power wiring for errors. Also check DC motor for internal grounding.



OTHER MESSAGES

The following are other HELP messages:SOME BIG BAD PROBLEM! ______________________________ Flash Code: 9/9

• This message should not occur!FACTORY OVERRIDE___________________________ Flash Code: (fast flashing)

• When the controller is first shipped, prior to initial calibration, it is configured in a special “fac-tory override” state. In this state, none of the normal shutdowns or interlocks will occur – the vehicle can be freely lifted/lowered and driven irrespective of any calibration needs, vehicle tilt, etc.

• As soon as an EZ-Cal is connected to the controller, the factory override state is ended. • If calibration does not occur, then the factory override state will recur if the EZ-Cal is discon-

nected and power is switched off/on.

IMPORTANT: – Never use a vehicle in factory override; this state is ONLY intended for use during manufacture! While factory override is active, the LED is rapidly flashed on/off.


TROUBLESHOOTING - - TROUBLESHOOTING CHART

TROUBLESHOOTING CHART

The following chart is a guide to help the technician find the area of a problem. In order to benefit from the information, you are advised to fully assess the symptoms by operating all machine functions. There may be some functions that operate while others may not. Record this information and proceed down the left-hand column until you find the failure scenario that best fits the problem. Refer to the information provided to the right for possi-ble causes and remedies. This unit contains a Microprocessor based control system which contains various safety features designed to protect itself and the operator in the event of a failure. The EZ-Cal scan tool will provide the technician with detailed information related to the failure. It is strongly recommended that the technician use the EZ-Cal to read any displayed messages before using this Troubleshooting chart.Information on the use of the EZ-cal tool plus helpful Flow Charts and graphs can be found earlier in this troubleshooting section. Please read and familiarize yourself with all of the information provided in the troubleshooting section before attempting to diagnose or repair the machine.

Table 4-4: Troubleshooting Chart

PROBLEM POSSIBLE CAUSE REMEDY/SOLUTION

General Power IssueNo operation from

Upper or Lower control station

Main Battery Switch turned OFF Located left of Lower Control BoxEmergency Stop Switch pushed or faulty; or Ignition Switch turned OFF or faulty

Upper or lower E-Stop will cut all power, as will the Ignition Switch in the Upper Control Box

Battery discharged or faulty cables Will receive 4-4 or 7-7 flash on GP400.Clean, service and charge battery; repair cables

Circuit Breaker Tripped Located in Lower Control Box PanelLook for short circuit and/or damage in wiring or high amperage draw at valve coils or engine actuators.

Damaged Upper Control Box harness Inspect the harnesses and harness plugs for damage or broken wires - May receive 6-6 flash code on GP-400 (CAN bus) or no power at all

Blown supply fuse Locate source of short circuit. Inspect/replace fuse located just below Main Battery Switch

Other fault in system monitored by GP400

Check HELP message on EZ-cal or check Flash Code for error

Functions from Lower Controls but not from

Upper Controls

Base/Platform select switch not in the Platform position, or switch malfunction

Ensure that the switch is in the Platform position; check switch function

Interlock Switch (Joystick) Check power to red wire (power to switch)and power to purple wire (power out of switch)at the joystick plug

Damaged Upper Control Box harness Inspect the harnesses and plug connections for damage or broken wires



Engine-Related IssuesStarter will not crank from upper or lower

stations

Battery discharged or faulty cables 4-4 or 7-7 flash on GP400.Clean, service and charge battery; repair cables.

Malfunctioning start relay or fuse Test/replace relay located on left hand side of engine;Test/replace fuse located near starter

Malfunctioning starter Test/replace starterStarter cranks but

engine will not startLow fuel level Check/fill fuel reservoirMalfunctioning fuel solenoid Test/replace fuel solenoid located on front of engine,

accessed from right sideMalfunctioning glow plugs (cold climates) Test/replace glow plug relay, fuse and glow plugsObstructed air filter Clean/replace air filterContaminated fuel Test/replace fuelOther engine issues See engine manufacturer’s troubleshooting guide

No high throttle Malfunctioning throttle relay, solenoid, or blown fuse

Test/replace throttle relay and/or throttle solenoid and fuse

Lift/LowerPlatform will not raise Excessive weight on platform Reduce weight to within platform capacity

Main Relief Valve out of adjustment Adjust Relief Valve to rated platform capacity; located on Function manifold - see Schematics section for location

Lift Valve SV-1 not energized Check wiring to lift valve;Check for EZ-cal message or flash code

Level sensor out of level(platform elevated above 10')

Reposition machine to firm level surfaceCheck level sensor signal using EZ-cal ID #s 2a-7 and 2a-8

Main system pressure inadequate Check pump output flow and pressureBattery discharged; no charge output Check battery voltage, alternator output (14.5 volts)

Clean, service and charge batterySystem interruption Check HELP messages using EZ-cal

Platform will not raiseover 35 ft. (10 m)

Outriggers must be deployed to raise platform to full height

All 4 outrigger legs must be supporting the machine’s weight; lower platform and operate auto-level switch; reposition machine if necessary

Malfunctioning outrigger limit switch(es) Adjust/replace outrigger limit switches located on each outrigger leg

Platform will not lower or lowers slowly

Maintenance lock in maintenance position Return maintenance lock to the stowed positionLowering valve not energized Check wiring to lowering valve located inside control

module; see Schematics section for locationLowering valve not shifting Clean debris/damage; replaceLowering orifice plugged Clean orifice located inside Function manifold - see

Schematics section for locationDown system diode failure Check/replace diode inside lower control boxSystem interruption Check HELP messages using EZ-cal

Emergency lowering not working

Auxiliary power unit malfunction Check APU located below lower control boxDown system diode failure Check/replace diode inside lower control boxLowering valve not shifting Clean debris/damage; replaceLowering orifice plugged Clean orifice located inside Function manifold - see

Schematics section for locationBattery discharged; no charge output Check battery voltage, alternator output (14.5 volts)

Clean, service and charge batteryEmergency Down switch failure Check/replace switch.





DriveNo drive function Lift/Drive select switch not in Drive

position or not operationalSelect Drive position (upper control box), check switch,check switch position from GP400 with EZ-cal (see EZ-cal ID# 2b-2) DLD

Drive valve not shifting (SVD1) Check connections at valveCheck Drive Valve for contaminationCheck Drive output from GP400 (See EZ-cal chart ID# 2f-6 & 2f-7)

Outrigger legs not raised off the ground Check for green indicator light on upper control box; raise outriggers until green indicator light illuminates

Malfunctioning outrigger limit switch(es) Adjust/replace outrigger limit switch(es) located on each outrigger leg

Planetary hub bypass engaged Check bypass plates located in the center of each planetary hub; should be convex--turn over if not

Brakes not releasing Check brake valve and brake system pressure - see Schematics section for location

Low pump stand-by pressure Check at Brake/Axle manifold--should be 300 psi (21 bar); adjust if necessary. See Schematics section for location

Drive system shut down (interlock) Check HELP and MODE message on EZ-CalNo drive elevatedNOTE: Maximum

elevated drive height is 35 feet (11 m)

Unit out of level Lower and operate on level surfaceLow pump stand-by pressure Check at Brake/Axle manifold--should be 300 psi (21 bar);

adjust if necessary. See Schematics section for locationOutriggers deployed Lower platform and retract outriggersSystem Interruption (interlock) Check HELP messages using EZ-Cal

Slow drive with platform stowed

High torque (slow speed) enabled Check Speed/Torque switch on upper controls;check 2-speed valve located on brake manifold - see Schematics section for location

Low pump stand-by pressure Check at Brake/Axle manifold--should be 300 psi (21 bar); adjust if necessary. See Schematics section for location

FWD MAX, REV MAX settings incorrect Reset drive speeds using EZ-calWheel motors not functioning correctly Inspect wheel motors for damage or wear

Poor gradeability or drive performance

High speed enabled Check Speed/Torque switch on upper controlsPlanetary hub bypass engaged Check bypass plates located in the center of each planetary

hub; should be convex--turn over if notWheel motors not functioning correctly Inspect wheel motors for excessive bypassLow pump stand-by pressure Check at Brake/Axle manifold--should be 300 psi (21 bar);

adjust if necessary. See Schematics section for locationIncorrectly adjusted or worn hydraulic pump

See Hydraulics section for pump adjustmentInspect or replace pump

Drive in one direction only

Drive valve not energized in one direction Check 12 volts to appropriate coil; check coil;check valve function (located on top of drive pump)

No output from GP400 Check switch position output from GP400 (see EZ-Cal ID# 4f-7 – FWD or 2f-9 – Reverse)

No low speed(high torque mode)

Speed/Torque switch inoperative Check continuity through Speed Select switch with wires disconnected terminals 2 & 1

Valve SV3 not functioning Check for 12 volts and ground to valveCheck for faulty valve spoolCheck switch position output from GP400(See EZ-cal ID# 2f-17)

EP1 poppet valve not functioning Check or replace valve (see hyd schematic for location)





No High Speed Speed/Torque selector switch inoperative Check continuity through Speed Select switch with wires disconnected

2-speed valve not functioning Check for 12 volts and ground to valveCheck for faulty valve spoolCheck switch position output from GP400(See EZ-cal ID# 2f-14)

SteerNo steer in either

directionLift/Drive selector switch in the Lift position

Switch must be in Drive position for steer operation

Joystick rocker switch malfunction Check continuity through rocker switch on green and yellow wires (right & left) with blue wire (input).

Steering valve malfunction Check steering valve for power, damage or contamination;Check switch position output from GP400 (see EZ-cal ID # 2f-11 & 2f-12)

System Interruption Check HELP messages using EZ-CalProportional valve malfunction Check variable signal to valve; check for contamination -

see Schematics section for location; See EZ-cal ID 2f-8

Hoses connected incorrectly See Schematics section for proper connectionPressure relief valve set too low Set steer relief valve to 2600 psi (179 bar) - see Schematics

section for locationSteers in one direction

onlySteering valve inoperative or stuck Inspect/replace steering valveNo power to steering coil Check for power and ground in both directions; repair

wiring; Check switch position output from GP400(see EZ-cal ID#s 2f-11 right & 2f-12 left)

System Interruption Check HELP and MODE message on EZ-CalSteers but not fully, or

steers slowlyFailure of one or both steering cylinder internal seals

Inspect/replace steering cylinder seals

Pressure relief valve set too low Set steer relief valve to 2600 psi (179 bar) - see Schematics section for location

King pin(s) seizing in the bore Disassemble and inspect;repair; replace bushings





Outriggers (Auto and Manual)No Auto - level

operationSystem senses platform elevation above 10 feet (3.2m)

Check elevation status using the EZ-cal (see ID# 2a-13);Recalibration of Height may be necessary (see Calibration section for instruction);See EZ-cal ID #2a-9 for analog input from height sensor in %

System interruption Check HELP messages using EZ-calOutrigger switch(es) malfunction Check outrigger switch(es) located in the upper control box;

Check GP400 for verification of operation--go to DIAGNOSTICS>SYSTEM> MODE (see EZ-cal ID# 2a-1)

Proportional Valve malfunction Check variable signal to valve; check for contamination - see Schematics section for location; See EZ-cal ID 2f-8

Level Valves malfunctioning Located on Function Manifold; Check valve for power or damage; check switch position output from GP400 (see EZ-cal ID# 2f-16 (extend) and 2f-17 (retract))

Auto-level operates but platform is not level

when cycle is complete

Level sensor not properly calibrated See Calibration section for proper level sensor calibrationUnit on too extreme an angle Relocate unit to more level groundLower control box loose Tighten all lower control box mounting screwsOutrigger leg switch(es) inoperative or out of adjustment

See EZ-cal ID #s 2d-9 through2d-12 to locate problem switch. ON=leg down and set.

One or more outrigger valves is sticking Located on each outrigger leg; Inspect valves for power, contamination or damage; Check switch position output from GP400 (see EZ-cal ID# 2f-20 through 2f-23)

Level cylinder hoses not connected in correct location

See Schematics section for correct locations

Outrigger valves wired incorrectly See Schematics section for proper plug connection. Relief valve out of adjustment Set steer relief valve to 2600 psi (179 bar) - see Schematics

section for locationNo Manual level

operationSee "No Auto-level Operation" for information




TROUBLESHOOTING - - HYDRAULIC PRESSURE ADJUSTMENT

HYDRAULIC PRESSURE ADJUSTMENT

• Before attempting to check and/or adjust pressure relief valves, operate the machine for 15 minutes or long enough to sufficiently warm the hydraulic fluid.

• Insert a 0-5000 psi gauge onto the pressure test port on the valve manifold using gauge adapter fitting MEC part no. 8434

Table 4-5: Hydraulic Pressure Settings

ADJUSTING RELIEF VALVES

• Remove the tamper proof cap.• Turn adjustment screw “IN” to increase pressure.• Turn adjustment screw “OUT” to decrease pressure.• When correct pressure is obtained replace tamper proof cap with a new one.

Do not operate pump with tamper proof cap removed. Fluid will emit under pressure.

Figure 4-10: Adjustable Valves Location

Model Drive Charge

5492RT 4500 PSI 310 bar 348 PSI 24 bar

Lift Steer/Outriggers

2800 PSI 193 bar 2800 PSI 193 bar

ART_3570

REAR OF MACHINE

GP1

P

FRONT

OF MACHINE

RV2

RV1

RV1Lift Relief

RV2Steer Relief

Gauge Port(Test Port)



ADJUSTMENTSCOUNTERBALANCE VALVES

The counterbalance valves, located on the lift and axle lock cylinders of the 5492RT, are set by the manufacturer and should not be adjusted for any reason. Replace any counterbalance valve that shows evidence of adjustment or tampering.

LIFT RELIEF (RV1)The Lift Relief Valve (RV1) should be checked during routine maintenance to ensure proper lift capacity. It will be necessary to remove the cap from the relief valve if adjustment is necessary. REMOVING THE CAP WHILE THE ENGINE IS RUNNING WILL RESULT IN FLUID LEAKAGE.To check Lift Relief valve setting, park the machine on a firm level surface free from overhead obstructions. Lift Relief Valve (RV1) should be set to 2800 psi (193 bar).

• Insert a 0-5000 psi gauge into the port GP of the Functions Manifold.• Extend the platform to full height with no load on platform.• Hold the switch for 10 seconds to get an accurate reading on the pressure gauge.• If pressure is LOW, adjust lift relief valve ¼ turn clockwise and recheck.• If pressure is HIGH, adjust lift relief valve ¼ turn counterclockwise and recheck.• Repeat until correct.

STEERING RELIEF (RV2)The steering Relief Valve (RV2) should be checked during routine maintenance to ensure proper steering function. It is necessary to remove the cap from the relief valve if adjustment is necessary. REMOVING THE CAP WHILE THE ENGINE IS RUNNING WILL RESULT IN FLUID LEAKAGE.Steering Relief Valve (RV2) should be set to 2800 psi (193 bar).

• Insert a 0-5000 psi gauge into the port GP of the Functions Manifold.• Energize the steering to full left.• Hold the switch for 10 seconds to get an accurate reading on the pressure gauge.• If pressure is LOW, adjust steering relief valve ¼ turn clockwise and recheck.• If pressure is HIGH, adjust steering relief valve ¼ turn counterclockwise and recheck.• Repeat until correct.



DRIVE PUMP ADJUSTMENTSThis section offers instruction on inspection and adjustment of pump components. Read through the entire topic before beginning a service activity.

Contamination can damage internal components and void your warranty. Take precautions to ensure system cleanliness when removing and reinstalling system lines

Standard Procedures

1. With the engine off, thoroughly clean the outside of the pump.2. If removing the pump, tag each hydraulic line. When you disconnect hydraulic lines,

immediately cap them and plug each open port to prevent contamination.3. Ensure the surrounding area is clean and free of contaminants like dirt and grime.4. Inspect the system for contamination.5. Check the hydraulic fluid for signs of contamination: oil discoloration, foam in the oil,

sludge, or metal particles.6. If there are signs of contamination in the hydraulic fluid, replace all filters and drain

the hydraulic system. Flush the lines and refill the reservoir with the correct filtered hydraulic fluid.

7. Before re-installing the pump, test for leaks.8. See the pump start-up procedure in Section 2.



Charge Pressure Relief Valve Adjustment

This procedure explains how to check and adjust the charge pressure relief valve.

1. Install a 1000 psi (50 bar) pressure gauge in charge pressure gauge port GCP on the Brake Manifold. This gauge shows charge pressure.

2. Install a 100 psi (10 bar) gauge at case pressure port L1, L2, or L3. This gauge shows case pressure.

3. Operate the system with the pump in neutral (zero displacement) when measuring charge pressure.

NOTE: Ensure charge pressure is properly set before checking pressure limiter. See Section 1.

4. The charge pressure relief valve setting for this pump is 348 psi (24 bar). This pres-sures assumes 1800 rpm pump speed, charge flow of 7 gal/min (26.5 l/min), and res-ervoir temperature of 120°F (50°C). The charge pressure references case pressure.

NOTE: At higher pump speeds or higher charge flows the charge pressure will rise over the rated setting.

Figure 4-11: Charge Pressure Adjustment

5. Rotate the adjusting screw clockwise to increase the setting; counter clockwise to decrease it. Subtract the case pressure reading from the charge pressure reading to compute the actual charge pressure.

NOTE: Pressure change per turn is dependant on charge flow entering pump.

6. While holding the adjusting screw, torque locknut to 13 lb-ft (17 Nm).

7. When you achieve the desired charge pressure setting, remove the gauges and plug the ports.

ART_3596

REAR OF MACHINE

GCP

T

Charge PressureAdjustment Screw& Locknut

Brake Manifold

Drive Pump



Pressure Limiter Adjustment

NOTE: Ensure charge pressure is properly set before checking pressure limiter.

At the Platform Controls, set the Speed/Torque Switch to HIGH SPEED (up). Position the platform such that it cannot drive and the wheels cannot rotate.

THIS PROCEDURE REQUIRE THAT THE DRIVE SYSTEM BE BROUGHT TO FULL PRESSURE WITH THE MACHINE IMMOBILIZED. THE MACHINE MUST BE SECURELY RESTRAINED BEFORE PERFORMING THIS PROCEDURE.

Figure 4-12: Brake Manifold

1. Install a 5000 psi (350 bar) pressure gauge in port GD of the Brake Manifold. Install a 1000 psi (50 bar) pressure gauge in port GCP of the Brake Manifold

2. Start the engine and run at idle.3. Use a 17mm wrench to loosen the lock-

nut.4. Activate the Drive Joystick until pressure

in the high side of the system loop stops rising. This pressure is the PL setting.

5. Release the Drive Joystick and adjust the PL setting using an internal hex wrench. Turn the adjusting screw clock-wise to increase the PL setting, counter clockwise to decrease it. The adjustment is very sensitive. Change per full turn is approximately 2176 psi (150 bar).

6. Repeat steps four and five until pressure read 4500 psi (310 bar). After adjust-ment, torque the locknut to 9 lb/ft (12 Nm). Do not over torque.

7. Shut down the engine. Remove gauges and replace plugs.

ART_3593

REAR OF MACHINE

GCP

T

REAR OF MACHINEGD

Pressure LimiterAdjustment Screws& Locknuts

HPRV Valve

Brake Manifold

Drive Pump

Brake Coil



Control Neutral Adjustment

All functions of the Electric Displacement Control (EDC) are preset by the pump manufacturer. Adjust the pump to neutral with the pump running on the vehicle with the engine operating. If adjustment fails to give satisfactory results, it may be necessary to replace the control or coils.

UNINTENDED MOVEMENT OF THE MACHINE MAY CAUSE INJURY TO THE TECHNICIAN OR BYSTANDERS. TO PROTECT AGAINST UNINTENDED MOVEMENT, SECURE THE MACHINE AGAINST MOVEMENT AND DISCONNECT THE BRAKE COIL WHILE SERVICING. SEE FIGURE 4-12 ON PAGE 4-38 FOR LOCATION OF COIL.

Figure 4-13: Control Neutral Adjustment

1. Install a 1000 psi (50 bar) gauge in each of the two servo gauge ports (M4 and M5). Discon-nect the external control input (electrical con-nections) from the control. Start the engine and operate at idle speed.

2. Use a 4mm internal hex wrench to hold the neutral adjusting screw stationary while loosen-ing the locknut with a 13mm wrench.

3. Observe pressure gauges. If necessary, turn adjusting screw to reduce any pressure differ-ential.

4. Rotate the neutral adjusting screw clockwise until the pressure increases on the gauge. Note the angular position of the wrench. Then rotate the neutral adjusting screw counter clockwise until the pressure increases by an equal amount on the other gauge. Again note the angular position of the wrench.

5. Rotate the neutral adjusting screw clockwise half the distance between the wrench positions noted above. The gauges should read the same pressure, indicating that the control is in its neutral position.

6. Hold the neutral adjusting screw stationary and tighten the lock nut. Torque to 7 lb/ft (10 Nm). Do not over-torque the nut.

7. When the neutral position is set, stop the engine, remove the gauges, and install the gauge port plugs. Reconnect the external control input.

NOTE: A small pressure differential of 22 psi (1.5 bar) or less is acceptable. Zero differential is usually not possible.

ART_3594

Neutral Adjustment Screw & Locknut

Port M5

Port M4



Mechanical Neutral Adjustment

SERVO ADJUSTMENT Figure 4-14: Servo Adjustment, Port M5 Side

1. Run engine at 1800 rpm.2. If using a PWM signal, ensure the

signal is off. Check the servo pressure gauges. Ensure the dif-ferential between M4 and M5 is less than 22 psi (1.5 bar).

3. Using a 3/4 in hex deep socket, unthread both servo cylinders 2-3 turns. This step ensures the servo cylinders have no contact with the servo piston.

4. Stroke the pump by turning the control eccentric screw, or by supplying current to solenoid C1, until the servo pressure at port M4 is 1 to 2 bar [14– 29 psi] greater than at port M5 and the system pressure gauges indicate displacement. Pressure should be greater at port MB. This also indicates the servo piston is in con-tact with the servo cylinder on side M5.

5. Slowly thread the servo cylinder on the M5 side in until the system pressure differen-tial starts to decrease. Maintain servo pressure differential between 1-2 bar [14-29 psi] during this step. Continue turning the servo cylinder in until the system pressure differential (between ports MA/MB) is less than 22 psi (1.5 bar). This procedure sets the servo and swash plate to mechanical neutral on the M5 side.

6. Repeat steps 1-5 but stroke the pump in the opposite direction by turning the eccen-tric screw in the opposite direction, or by supplying current to solenoid C2. Reverse gauge locations (M4 for M5, MB for MA) from those stated above since the pump is now stroking the other direction.

7. Remove all gauges and replace gauge port plugs.VERIFY NEUTRAL SETTING

1. If using a PWM signal to set mechanical neutral, check that servo pressure differen-tial is less than 22 psi (1.5 bar). Refer to "Control Neutral Adjustment" on page 4-39.

2. To verify mechanical neutral, provide current to solenoid C1, or turn neutral adjust-ment screw, until the servo pressure differential is 3 bar [43 psi]. The system pressure differential must be below 22 psi (1.5 bar). Repeat test on solenoid C2 side.

3. The current required to set the servo pressure differential to 3 bar [43 psi] should be the same for each solenoid.

4. If using neutral adjustment screw to set mechanical neutral, reset control neutral. Refer to "Control Neutral Adjustment" on page 4-39.

ART_3595

M5Servo

Locking Plate

Servo Cylinder

Servo Locking Bolt


Section 5SCHEMATICS

CONTENTS PAGE

Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

FIGURES PAGE

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Function Manifold, MA1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Brake Manifold, MA2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Drive Manifold, MA3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Electric Schematic, Lower Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7Electric Schematic, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Electric Schematic, Upper Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9Upper Controls Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10Lower Controls Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11


HYDRAULIC SCHEMATICS -

HYDRAULIC SCHEMATICS

The following table applies to Figure 5-1, Figure 5-2, Figure 5-3 and Figure 5-4.

Callout Description

BR1 - BR4 Brake, Integral to the torque hubsC1 Valve, Drive directionalC2 Valve, Drive directionalCBV1, CBV2 Counterbalance Valve, Lift cylinder holdCBV3, CBV4 Counterbalance Valve, Axle lock cylindersCYL1 Cylinder, Hydraulic liftCYL2 Cylinder, Hydraulic liftCYL3, CYL4 Cylinder, SteerCYL5, CYL6 Cylinder, Axle lockCYL7 - CYL10 Cylinder, OutriggerEPFR1 Flow Regulator, Diverts unused oil to tankFD1 - FD3 Flow Divide Valve, drive traction controlFL1 Filter, Hydraulic oil returnFL2 Filter, Charge pumpLS1 Check Valve, Drive signal for Axle LockMA1 Manifold, MainMA2 Manifold, axle lock, 2-speed, brakeMA3 Manifold, DriveMT1 - MT4 Wheel Drive MotorORBV1 - ORBV4 Outrigger Blocking Valve, O/R controlORF1 Orifice, Flow regulator controlORF2 Orifice, Lower max speed controlORF3 Orifice, Steer max speed controlORF4 Orifice, Brake apply controlORF5 Orifice, 2-speed shift controlORF6 - ORF8 Orifice, Drive flow-divide bypassP1 Pump, Drive hydrastaticP2 Pump, Lift, steer and outriggersP3 Pump, Emerg power unitRV1 Relief Valve, Lift, Lower max pressure RV2 Relief Valve, Outrigger, steer max pressure SP1 Proportional Valve, Speed controlSV1 Solenoid Valve 5-way, 3 pos, Steer directionalSV2 Solenoid Valve 2-way, 2 pos, Axle LockSV3 Solenoid Valve 2-way, 2 pos, 2-speed shiftSV4 Solenoid Valve 2-way, 2 pos, Brake releaseSVD1 Solenoid Valve 4-way, 3 pos, Lift, LowerSVD2 Solenoid Valve 4-way, 3 pos, Outrigger directional



Figure 5-1: Hydraulic Schematic

ART_

3538

5492

RT

H

YD

RA

UL

IC S

CH

EM

AT

IC

BR

AK

E

AXL

ELO

CK

2-S

PEE

DSH

IFT

BR

AK

ER

ELE

AS

E

MA

NIF

OLD

MA

2

CY

L5

CB

V3

CY

L6

CB

V4

CY

L7C

YL8

CY

L9C

YL1

0

OR

BV

1O

RBV

2O

RBV

3O

RBV

4

CY

L1

CY

L2

CB

V1

CB

V2

CY

L3C

YL4

FUN

CTI

ON

MA

NIF

OLD

MA

1 PR

OPO

RTI

ON

ALVA

LVE

FLO

WR

EGU

LATO

RLI

FTR

ELIE

F

LIFT

/LO

WER

OU

TRIG

GE

RD

IREC

TIO

NAL

STE

ERD

IRE

CTI

ON

AL

O/R

, STE

ER

REL

IEF

P3AU

X. P

UM

PH

YDR

AU

LIC

RES

ERVO

IR

FL1

(CH

ARG

EP

UM

P TE

ST)

DR

IVE

PUM

PP

1

CH

AR

GE

FILT

ERFL

2

DR

IVE

MA

NIF

OLD

MA3

MT1

MT2

MT3

MT4

BR

1BR

2B

R3

BR

4

P2

AC

CE

SS

OR

YPU

MP



Figure 5-2: Function Manifold, MA1

5492RTFUNCTIONS MANIFOLD MA1 ART_3539

PAUX

P

T

FRONT

OF MACHINE

STA

STB

ORA

ORB

LFTLW

R

PA

UXP

TREAR OF MACHINE



Figure 5-3: Brake Manifold, MA2

ART_3540

5492RTBRAKE MANIFOLD MA2

REAR OF MACHINE

AXLE

2SPD

BRKGCP

CP

T

REAR OF MACHINE

AXLE

2SPD

BRK

B

GDA

T



Figure 5-4: Drive Manifold, MA3

5492RTDRIVE MANIFOLD MA3 ART_3541

D1

FRONT OF THE MACHINE

D2D7

D8

B

A

D5

D3

D6

D4

REAR OF THE MACHINE


ELECTRICAL SCHEMATICS -

ELECTRICAL SCHEMATICSFigure 5-5: Electric Schematic, Lower Control Box

ART_354217682

SCHEMATIC Model: / Serial #

Publication Art #:Reference Art #:

Lower Controls

5492RT 1 of 3

GP400: 21 510 411

5492RT | 17400001- UP

4

2 1

3



Figure 5-6: Electric Schematic, Base

ART_354317682



Chassis

5492RT 2 of 3

GP400: 21 510 411

5492RT | 17400001- UP

BLK

ANGLE TRANS

J-4

414

413

412

J-8

J-9

To Platform414

413

412



Figure 5-7: Electric Schematic, Upper Control Box

ART_354417682



Upper Controls

5492RT 3 of 3

GP400: 21 510 411

5492RT | 17400001- UP

24

71

438

448 449 522 523

OUTPUTS

J-6

To Base

J-7

Section 4 -...

Documents

Transcript of Section 4 -...